AXIAL FLOW FANS FOR UNDERGROUND MINES

A SEMINAR REPORT SUBMITTED IN PARTIAL FULFILLMENT OF THE

REQUIREMENTS FOR THE DEGREE
OF
BACHELOR OF ENGINEERING
IN
MINING ENGINEERING
BY
SHIVRAJ SUMAN -15BMI70037

DEPARTMENT OF MINING ENGINEERING

FACULTY OF ENGINEERING AND ARCHITECTURE
JODHPUR-342001
2016

A SEMINAR
ON
AXIAL FLOW FANS FOR UNDERGROUND MINES

BY

SHIVRAJ SUMAN

UNDER THE GUIDENCE OF

Dr. D.M. SURANA
FORMER PROF. & H.O.D

DEPARTMENT OF MINING ENGINEERING

FACULTY OF ENGINEERING AND ARCHITECTURE
JODHPUR-342001
January 2016

ii

ABSTRACT
Developed The practice of ventilation is continually evolving with new technological
advances in the mining industry. In recent years the advances in diesel engine technologies,
ventilation modeling software, and ventilation management capacities have redefined the
historical methods used to evaluate systems. The advances re-evaluate previous methods
used to calculate the airflow requirements for the dilution of diesel exhaust fumes. Modeling
software has become an integral part of planning and developing ventilation systems in
partnership

with

graphical

mine

design

software

packages

to

generaterealistic

representations of the mine. Significant advances in ventilation control strategies through

remote sensors and monitoring capabilities have been developed to results in cost savings.
Though there has been much advancement in mine ventilation technology, the practices and
basic ventilation principals enacted through the ventilation engineer cannot be placated with
technological advances only.

The design for the pre-ventilation system of the Okaba Coal deposit required 145 m3/s of air
with a main fan pressure of 2.73 kPa, with four booster fans of air volume, 110 m3/s, 125
m3/s, 95 m3/s, 105 m3/s with fan pressure of 0.63 kPa, 0.87 kPa, 0.47 kPa, 0.50 kPa and
with exhaust fan of 70 m3/s at fan pressure of 0.38 kPa respectively, all required to ventilate
the mine. The design is basically on longwall mine as it met the geological condition,
engineering properties of the deposit and the design parameters to ensure better safety of
miners and offers a great coal recovery.

iii

ACKNOWLEDGEMENT
The most pleasant point of presenting a report is the opportunity to thank those who have
contributed to it. Unfortunately, the list of expressions of thankfulness, no matter how
extensive, is always incomplete and inadequate. Indeed this page of acknowledge shall
never be able to touch the horizon of generosity of those who tendered their help to me.
First and foremost, I would like to express my deep and sincere gratitude to my guide, Prof.
D.M. Surana, for his guidance and persistent help, this report would not have been possible.
I am thankful to Prof. A.S. Sheoran Head, Mining Engineering Department MBM Engg.
College Jodhpur, for giving me an opportunity to prepare this seminar report.
An assemblage of this nature could never have been attempted without reference to and
inspiration from the works of others. I acknowledge my indebtedness to all of them.

Date:

SHIVRAJ SUMAN
ROLL NO.:15BMI70037
B.E.IV YEAR

iv

CERTIFICATE
This is to certify that Mr. SHIVRAJ SUMAN, student of Final Year B.E. (Mining
Engineering) has submitted the seminar report entitled AXIAL FLOW FANS IN
UNDERGROUND MINES Which is record of his own work carried out under my
guidance.

Dated
Dr. D.M SURANA
FORMER PROF. & HEAD
Department of Mining Engineering
M.B.M Engineering College,
JODHPUR

CONTENTS

ABSTRACT ii
ACKNOWLEDGEMENT.. iii
CERTIFICATE... iv
CONTENTS ..v
LIST OF FIGURES vi
LIST OF TABLES vii
1.0
2.0

INTRODUCTION1
PROCEDURE FOR FAN SALECTION OF MODERN ...2
AXIAL FLOW FAN
2.1 Laws of fan.2
2.1.1- fan vol. vs fan pressure graph3
2.1.2- mine char. for low,medium& high resistance...4
2.2 Fan selection using fan total pressure to save energy4
2.2.1- why fan total pressure4
2.2.2-fan and pressure .4
2.2.3- using fan static pressure for fan selection.5

3.0 FEATURE OF FAN...8

3.1 Technical features9
3.1.1 blade profile ..9
3.1.2 multi stage A.A.F over centrifugnal fan .11
3.1.3 dimension13
3.1.4 energy consumption.14
4.0 EXAMPLE OF SOME LARGE MINES15
5.0 SAFETY ASPECTS15
6.0 CONCLUSION...16
7.0 REFRANCES..17

vi

LIST OF FIGURES
FIGURE

PAGE NO.

1: Air flow in underground mine(Akande and Moshood,2013)

2 :pressure profile in the inlet and outlet of a fan(Cenmark,2011)

3: fan selection made by matching the pressure drop across the

system with fan static pressure(Cenmark,2011)

4: : fan selection made by matching the pressure drop across the

system with fan total pressure(Cenmark,2011)

5: : The schematic of axial flow fan( Vutukuri &Lama ,1986)

6: Forces acting on a typical aerofoil section of axial flow fan

10

(Panigrahi and Mishra,2014)

7:structure and air flow mechanism of axial flow fan
(www.orientamotar.com,2014)

13

8: Line diagram of various feature of axial flow fan

15

(www.marathonelectric.in,2015)

LIST OF TABLES & GRAPH

TABLE & GRAPH

PAGE NO.

1 Graph : relation between fan volume vs fan static pressure

(Hartman and wang,2011)
2 Graph : relation between fan volume vs fan pressure(Misra,1986)

3
4

1 Table : : fan specification- impellers

(Axial flow fan general information, Fantech,2008)

13

vii

1. INTRODUCTION
An axial flow fan moves air or gas parallel to the axis of rotation. By comparison,
acentrifugal or radial flow fan moves air perpendicular to the axis of rotation. Axial flow
fans are better suited for low-resistance ,high-flow applications, whereas centrifugal flow
fans apply to high-pressure resistance ,low-flow conditions. Typically, the types of fans
discussed in this manual can handle resistances up to approximately 1 in. of water. Axial
fans can have widely varied operating characteristics depending on blade width and shape,
number of blades and tip speed .The most common type of fan for air-cooled heat exchanger
(ACHE) is less than 4.2m.diameter and has four blades. The most common type for wet
cooling towers is 8.4m. diameter and has eight blades. A typical ACHE fan is shown in
Fig1(Krog and Grau,2012).

Figure1:Airflow in an underground mine(Akande and Moshood,2013)

2.0PROCEDURE FOR SELECTION OF MODERN AXIAL FLOW FAN

2.1-Laws of Fan
The fan laws are a set of proportionalities relating each of the following parameters of
airflow with fan speed (n), air density () and impeller diameter (d).

Air pressure (p)

Airflow quantity (Q)

Power developed (PPOW)

Through extensive experimentation and derivation the following direct proportionalities

have been arrived.
(a) For varying speed but with constant air density and impeller diameter:
- Quantity varies directly as the speed .
- Pressure varies as the square of the speed .
- Power varies as the cube of the speed .
- Efficiency is constant
(b) For varying density but with constant speed and impeller diameter:
- Quantity remains constant
- Pressure varies directly as the density
- Power varies directly as the density
- Efficiency is constant
(c) For varying impeller diameter but with constant speed and air density:
- Quantity varies as the cube of the impeller diameter
- Pressure varies as the square of the impeller diameter
- Power varies as the fifth power of the impeller diameter
- Efficiency is constant

2.1.1- Fan volume vs fan static pressure graph:-

Graph 1:relation between fan volume vs fan static pressure(Hartman and wang,2011)

Now, let us draw new curves for this same fan when it is run at a speed of 798 RPM and
handling air at a density of 1.04 kg/m3.
At the original speed of 600 RPM and air density of .2 kg/m3, the fan at its design point will
deliver 115 m3/s at 1370 Pa using 225 KW of input power and giving an efficiency of 70.20
%. (Banerjee,2003).

2.1.2- Mine characteristic for low ,medium and high resistance:-

Graph 2: relation between fan volume vs fan pressure(Misra,1986)

When we install a fan in a mine, its performance will be determined by the point at which
the mine characteristic cuts the fan characteristic. The mine or system characteristic is a
curve which shows how the pressure drop across the mine varies as the quantity of air
varies. The mine characteristic curve can be drawn using the relation
P = RQ2 which was discussed earlier.

If we know the value of mine resistance (R), we can tabulate the values of P for different
values of Q. These values can then be plotted and we get mine characteristic curves. The
mine characteristic for low, medium and high resistance is shown in Fig.(Hartman
,Mutmansky and Wang,2012).
2.2 Fan Selection Using Fan Total Pressure Energy
2.2.1Fan and Pressure:-A fan is a device designed to primarily deliver flow, usually of air, at
relatively low pressure. The fan has an inlet opening for air to enter the fan and an outlet
opening for air to leave the fan. The flow through these openings is the same and creates a
velocity in each of these openings. The mo- tor, usually an electromotor, delivers energy to
4

the fan impeller and the impeller transforms the energy into the energy in the air handled by
the fan. If we define control surfaces at the inlet and outlet openings, the energy in the air
delivered by the fan is the difference between the energy of the air in the outlet opening
minus the energy in the air in the inlet opening of the fan.
This energy has two components, static and dynamic. Since the flow is equal for both inlet
and outlet, we may define the energy addition by the change in pressure between the two
openings. The fan total pressure is then defined as the difference of the total pressures in the
fan outlet and inlet openings. The relations among these pressures are depicted in Figure
(Cenmark,2011).

Figure 2:pressure profile in the inlet and outlet of a fan(Cenmark,2011)

2.2.2-Using Fan Static Pressure For Fan Selection:-First, we must stress that the fan
performance is usually presented in terms of FTP vs. flow or FSP vs. flow. In Figures and 3
both presentations are used simultaneously for a typical utility centrifugal fan size 24 in. (0.6
m). The requested operating point of the system is 13,000 cfm (6135 L/s) at 1.5 in. w.g. (374
Pa) pressure at standard air density.
In Figure 3 the system pressure drop has been matched with FSP, and it was found that the
fan speed would be 1,035 rpm, and the fan would need a power of 6.22 bhp (4.64 kW). But,
in reality, the fan at that speed would operate at a flow of 13,625 cfm (6430 L/s) at a system
pressure drop of 1.65 in. w.g. (411 Pa) The flow in the sys-tem is about 5% higher, and the
power need is 6.05 bhp (4.51 kW). In Figure the system pressure drop has been matched
with FTP, and it was found that the fan speed is 989 rpm, and the fan would need a power of
5.29 bhp (3.95 kW). The flow now matches the requirement, the fan speed is down by
almost 5%, and the power is down by 12.5%.

Figure 3:fan selection made by matching the pressure drop across the system with fan static
pressure(Cenmark,2011)

The benefits of the correct match are lower fan speed, lower sound and significantly lower
power. We can see that the selection of fans must be done by matching the fan performance
(total pressure vs. flow) with the system requirement. Many fan manufacturers present performance data in the form of multi-rating tables, which include values of flow, static
pressure, speed and power.
Conversion of these data to total pressure is simple (the velocity pressure is calculated from
the flow and outlet area), but it is assumed that the connection of the fan to the system is
such that the conver-sion of velocity pressure to static pressure at the outlet of the fan is
identical to the conversion experienced in the test set-up from which the data were derived.

Figure 4: fan selection made by matching the pressure drop across the system with fan total
pressure(Cenmark,2011)

The use of total pressure makes this assumption obvious, while the use of static pressure for
selection, while matching the flow to the required value, does not call into question the
validity of the selection.(Cenmak and Murphy,2011)
3.0- FEATURE OF FAN
3.1- Technical Feature
3.1.1- Blade Profile :-A fan is simply a machine which develops the pressure necessary to
produce the required airflow rate and overcome flow resistance of the system by means of a
rotating impeller using centrifugal or propeller action, or both. The axial flow fans are
commonly used in mine ventilation in lieu of centri-fugal fans due to high efficiency,
compactness, non-overlo-ading characteristics, development of adequate pressure, etc.
(Herdeen and Sullivian,2003).
The axial flow fan in its simplest form as diagrammatically shown in Figure 1 incorporates
a rotor, which consists of a hub fitted with aerofoil section blades in a radial direction. The
blades or vanes which constitute the main component of axial flow fan are the surfaces that
work by means of dynamic reaction on the air and develop positive air pressure during their
rotation due to the development of lift force.
The forces acting on a typical aerofoil section of an axial flow fan blade are shown in
Figure . The lifting force acts at right angles to the air stream and the dragging force acts in
the same direction of the air stream and is responsible for losses due to skin friction.
(Panigrahi and Mishra,2014)

Figure 5: The schematic of axial flow fan( Vutukuri and Lama ,1986)
The efficiency of axial flow fans is greatly dependent on the profile of the blade, and the
aerodynamic characteristics of the fan blades are strongly affected by the shape of the blade
cross section.
The cross section of fan blades is of a streamlined asymmetrical shape, called the blades
aerodynamic profile and is decisive when it comes to blade performance. Even minor
alterations in the shape of the profile can greatly alter the power curve and noise level.
Therefore, it is essential to choose an appropriate shape with great care, in order to obtain
maximum aerodynamic efficiency.
An aero-dynamic profile with optimum twist, taper and higher lift-drag ratio can provide
total efficiency as high as 8592%. The axial flow fan blades are of aerofoil sections and the
idea behind using aerofoil blades is to maintain the proper stream-lining of air to reduce
losses caused due to form drag as well as from strength considerations (Panigrahi et.
Al,2009).

Figure 6:Forces acting on a typical aerofoil section of axial flow fan(Panigrahi and
Mishra,2014)

10

3.1.2- Multi Stage A.F.F. Over CentifugalFan :(a) Axial Flow Fan:

(b)Centrifugal Fan:
(1) Forward curved impellers:
Blades curve towards the direction of rotation.
Fans have low space requirements and low tip speeds.
Used against low to moderate static pressures.
Not recommended for dust or particulate that would adhere to blades.
(2) Radial impellers:
Blades are in a radial direction from the hub.
Fan have medium tip speeds.
Radial blade shape resist material build up.
Can handle either clean or dirty air.
(3)Backward inclined/curved impellers:
Blades are inclined opposite to the direction of fan rotation.
High fan efficiency and relatively low noise levels.
Blade shape is conducive to material buildup.
(Deshmukh vol. 2,2005)

11

Figure7:structure and air flow mechanism of axial flow fan

(www.orientamotar.com,2014)
3.2-Dimensions
(a) Blades:-The blades have been designed for optimal performance, for both aerodynamic
needs as well as noise characteristics. They are available in a range of materials as shown
below:(b) Impeller Ranges:Diameters
Blades Hub Dia.(mm)
315 to 900
5 or 10
150
560 to 1000
7 or 14
250
800 to 1250
3 or 6
255
800 to 1400
3, 6, 9
350
1000 to 1800 3, 6 or 9
400
1250 to 2000 3, 6, 9 or 12 550

Materials
GRP , Nylon, Alum. or Anti-static GRP
GRP, Nylon, Alum. or Anti- static GRP
GRP, Nylon, Alum. or Anti-static GRP
GRP, Nylon, Alum.or Anti-or 12 static GRP
GRP or Aluminium
GRP or Aluminium

Table 1: fan specification- impellers(Axial flow fan general information, Fantech,2008)

The stress limits of the blades vary from one material to another and simplified criteria are
incorporated on the curves. However, if selecting fans using our interactive product
selection CD, you may find solutions with higher pitch angles are chosen; these selections
are quite acceptable .It should be noted that, as we are constantly reviewing the materials we
use, these limits may be extended.
(c) Hubs:-All hubs use Fantech TECH-LOCK taper bushes as standard with one
exception. The bush ensures ease of fitting and removal of the impeller from the motor shaft
12

should adjustment of the pitch angle, cleaning or repair of the impeller prove necessary. The
exception is for bores above 65mm and 85mm diameter for the 400mm and 550mmdiameter
hubs respectively. In these cases we supply impellers with simple through-bores.

(d) Fixings:-All impellers are assembled using high-tensile, zinc-plated set screws and selflocking nuts.

(d) Handing:-Right and left-hand blades are available enabling the selection of contrarotating or multi-stage axial flow fans up to 1400mm diameter. If contra-rotating fans of a
larger diameter are required please refer to our sales department.

(e) Standard Material:-GRP blades will be supplied for normal clean ventilation applications
as standard except where otherwise specified, or where local regulations prohibit their use.

(f) Balance:-The balance of all impellers is carefully checked to ensure vibration-free

running.
(g) Fully-adjustable Blades:-All impeller pitch-angles are fully adjustable. For the Elta
Range, up to size 1400, the required blade angles are set on jigs but for sizes up to 1000 may
also be set utilizing the graduated scale at the root of each blade. For the Elta 2000 Range
pitch angle setting is by protractor.( Axial flow fan general information, Fantech,2008).

13

Figure 8: Line diagram of various feature of axial flow fan(www.marathonelectric.in)

4.0-EXAMPLE OF SOME LARGE MINES WHERE AXIAL FLOW FANS USED

The deepest mines in the world are the TAU TONA and SVUKA gold mine of South
Africa.
The TAU TONA Mine or western deep no. 3 shaft is a gold mine in south Africa. At
3.9 km deep it is currently home to he worlds deepest mining operations rivaled
only

by

mponeng

gold

mine

with

which

it

competes

for

no.

ranking.(www.anglogold Ashanti.com,2015)

ANGICO-EAGLE LARONDE mine of north America.

The design of a major underground ventilation is a complex process in this largest
mine, the estimate air volume required for the proper ventilation while taking into
consideration ,the no. and size of equipment as well as for mineral production
.Mineralized zones at santa nino are up to 800 m long by upto 700m deep for a
distance of almost 5 km.(www.agapito.com,2015)

14

Uranium mine in Pribram, Czech Republic of Europe.

BERGWERK SAAR in Saarland Germany.

Mount Isa Queenland Australia.

Platinum Palladium mines of Merensky Reef South Africa.

HUTTI GOLD MINE karnatka India.

5.0- SAFETY ASPECTS

Mine fan should be continuously operated, except as otherwise approved ventilation

plan ,or when intentionally stopped for testing of automatic closing doors and
automatic fan singal devices, maintenance or adjustment of the fan.

When a main mine fan is intentionally stopped and the ventilating quantity provided
by the fan is not maintained by the back up fan system only persons necessary to evaluate the effect of the fan stoppage or restart.
Mechanished equipment shall be shut off before stopping the fan.
Electric power circuits entering underground areas of the mine shall be
deenergized.

When a back up system is used that does not provide the ventilating quantity provide
by main mine fan, persons may be permitted in the mine and electric power circuits
may be energized as specified in the approved mine ventilation plan.

15

If the unusual variance in the mine ventilation pressure is observed,or if an electrical or

mechanical deficiency of main mine fan is detected,mine for main or equivalent mine
official or in the absence of the mine foreman notified immediately and appropriate
action or repairs shall be instituted promptly.

While persons are underground a responsible person designated by operator shall

always be at a surface location where each main mine fan singal can be seen or heard.

The area within 30m. of main mine fan and intake air opening shall be kept free of
combustible materials ,unless alternative precautions necessary to provide protection
from fire or other product of combustible are approved in the ventilation plan.

If multiple mine fans are used the mine ventilation system operated during fan
stoppages shall be intrinsically safe.(www.fansafety.com)

6.0- CONCLUSIONS
An air screw fan or axial flow fan pushes the air toward in the direction parallel to the axis
i.e. axially without changing the direction of air current unlike in the centrifugnal fan.An air
screw fan require less space in installation compared to the centrifugnal fan.

On the reversal of the axial flow fan water gauge developed and quantity are much less
about to 50 % of the original. Quantity of air can be varied within wide limit in the case of
air screw fan by the varying the pitch of the blades. An air screw fan is more suited for low
water gauge and high volume but an axial flow fan however can be conventionally used for
developing high water gauge by installation of statges .An air screw fan is convient as an
underground booster fan due to ease of installation and the requirement of
space.Understanding and recognizing warning sign of air axial flow fan will helpful in
reduce the injury and accident in underground mines.(www.axialflowfaninfo.com)

16

REFERENCES:
Akande,J.M. and Moshood,O. 2013, Modelling of okaba underground coal mine ventilation
system. International journal of engineering & technology,pp 766-768.

Banerjee, S.P. 2003, Mine ventilation fan laws,Lovely prakashan, dhanbad India.pp 1-7.

Cenmark ,J. and Murphy, J. 2011, Select fans using fan total pressure to save energy.
Ashrae journal,pp 45-47.

Fan specification- impellers,Axial flow fan general information, Fantech,2008

Feature of axial flow fan, www.marathoelectic.com, 2015.

Keith ,W.,Brian P.and Daniel S. 2014,The practice of mine ventilation engineering,

International journal of mining science and technology,pp 168-170.

Krog, R.B. and Grau, R.H. 2012, Fan selection for large-opening mines: vane axial or
propeller fans which to choose ,U.S. Bureau of mines,pp 2.1-2.3.
Krog ,R.B., Grau, R.H.,Mucho, T.P. and Robertson ,S.B. 2004,Ventilation planning layout
for large opening mines,SME preprint Littleton,co: society for mining,metallurgy,pp 1-9.
Meyer, J. and Marx,W.1999, The minimizing of pressure losses in a fan drift-mine shaft
intersection, using computational fluid dynamics,R&D journal vol. 9, No. 3,pp 1-3.
Panigrahi, D.C. and Mishra, D.P. 2014, Cfd simulations for the selection of an appropriate
blade profile for improving engrgy efficiency in axial flow mine ventilation fans. Journal of
sustainable mining, pp 15-17.

Structure of axial flow fan,www.orientamotar.com,2014.

17

18